Customized orthopedic sole insert and method

ABSTRACT

A customizable sole insert for a shoe, the sole insert comprising: a top layer having a first plurality of holes through the top layer; a middle layer having a conforming and curable hardening material; a bottom layer having a second plurality of holes through the bottom layer; wherein the top layer, middle layer, and bottom layers are fastened together by a fastener; wherein a fluid applied to the middle layer causes the middle layer to cure; wherein the middle layer conforms to a plantar aspect area or sole of a foot of a user. Further comprising: a top cover attached to to a top outside surface of the top layer; and, a bottom cover attached to a bottom outside surface of the bottom layer. The customizable sole insert has a method for constructing the sole insert and a method for activating the sole insert.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of, and claims the benefit of priority from, U.S. Provisional Patent Application No. 62/857,334 filed Jun. 5, 2019

FEDERALLY SPONSORED RESEARCH

Not Applicable

FIELD OF INVENTION

This invention relates to orthopedic inserts for shoes, more particularly, to customizable orthopedic inserts for shoes and a method of manufacturing and activating the customizable insert for a particular user quickly and efficiently.

BACKGROUND

The human foot is a unique structure that can be very flexible or very rigid when a person walks. The human foot has twenty-six bones and thirty-three joints that are connected by a plethora of muscles, tendons, and ligaments. Thus the internal locking and unlocking of the bones and joints in the person's foot will not work properly if there is abnormal alignment. If such an abnormal alignment is present, the muscles in the lower extremities will be required to work harder to control the alignment of bones and joints. As a consequence, these muscles will fatigue quicker. And, once the muscles fatigue, the person will experience pain and discomfort because the muscles can no longer compensate for the abnormal alignment of the foot and ankle.

Many developments have been made in the prior art that address abnormal alignment of the foot and ankle. Besides invasive surgery, sole inserts for shoes have been developed for alignment issues. Often, these inserts are positioned between the bottom or plantar aspect of a person's foot and the shoe. The custom sole inserts are designed to support the bones and joints, maintain the normal alignment, and redistributes the pressure exerted by a person's body weight upon the plantar aspect of the foot so that the person can walk with greater stability and comfort.

A typical method known in the prior art for manufacturing customize sole inserts requires a plaster cast of the foot of the person or patient that is then used to customized the sole inserts along with any required modifications according to the specific needs of the patient as determined by the attending podiatrist. This type of procedure is expensive, and requires a substantial amount of time between the initial plaster cast and the final product, sometimes on the order of weeks. Therefore, a patient must endure the pain of improper alignment until the insert is made to the satisfaction of the attending podiatrist. Also, due to the expense, a patient normally cannot afford additional inserts and will typically use the same insert when wearing different shoes, which may be unhygienic and may create new alignment issues.

More recent prior art has attempted to address the problems associated with the expense and time for making a custom inserts. U.S. Pat. No. 7,017,218 illustrates a method for making a custom insert using water injected through a syringe to react with a woven polyurethane casting material. A disadvantage of the disclosure provided in U.S. Pat. No. 7,017,218 issued to Nguyen is that the water injection system requires additional tools, i.e., the injector, to be inserted into and through the layers, which may hurt and damage the user or the custom insert if the injector is improperly used or handled.

There is a need for customizable shoe inserts that can be formed and cured faster based on the user's needs and current shoes. There is also a need for a ready to use insert that requires less tools to form the shoe inserts.

OBJECTIVES

To provide a method for making and customizing a sole insert for a shoe quickly using a layer of moldable material which can be permanently hardened once a customized shape is obtained. To provide a sole-insert specific to the needs and requirements of a patient. To provide an insert which is not expensive to manufacture, and, as a consequence, a user may be able to afford to purchase multiple inserts for other shoes worn by the user. To reduce the need for a supervising podiatrist. And, to allow the user to customize the sole insert at a time and place of the user's choosing.

BRIEF SUMMARY OF THE INVENTION

A customizable sole insert for a shoe, the sole insert comprising: a top layer having a first plurality of holes through the top layer; a middle layer having a conforming and curable hardening material; a bottom layer having a second plurality of holes through the bottom layer; wherein the top layer, middle layer, and bottom layers are fastened together by a fastener; wherein a fluid applied to the middle layer causes the middle layer to cure; wherein the middle layer conforms to a plantar aspect area or sole of a foot of a user. Further comprising: a top cover attached to to a top outside surface of the top layer; and, a bottom cover attached to a bottom outside surface of the bottom layer. The customizable sole insert has a method for constructing the sole insert and a method for activating the sole insert.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a customizable insert sole.

FIG. 2 is an exploded view of a plurality of layers of the customizable insert sole.

FIG. 3 is a perspective view of the customizable insert that has been formed to the user's foot.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided So that this application will be thorough and complete, and will fully convey the true scope of the invention to those skilled in the art. The terms “patient,” “user,” “wearer,” and “person” are interchangeable and have the same meaning.

A device for a customized sole insert 10 and method for making the customized sole insert 10 for use with a foot 1 may be described herein. In most embodiments, at least one of the customized sole insert 10 may be placed within at least one shoe 3. In most embodiments, Referring to FIG. 1, the sole insert 10 may comprises a top layer 20, a moldable middle layer 30, and a bottom layer 40. In most embodiments, the sole insert 10 may come in a plurality of pairs 12. In some embodiments, the sole insert 10 may be based on a right foot profile, a left foot profile, and/or a universal foot profile. In most embodiments, the top, middle, and bottom layers 20, 30, 40 may be constructed with a very high arched shape 18 to conform with high arches of the foot 1.

In most embodiments, the top layer 20 and the bottom layer 30 may be perforated with a first and second sets of a plurality of holes 22, 42 (FIGS. 1-2) that may provide a pathway through the top and bottom layers 20, 40 for a fluid 5. In most embodiments, the fluid 5 may contact the moldable middle layer 30 that may be made of a moldable material, which may hardened on contact with the fluid 5. In some embodiments, the top and bottom layers 20, 40 may be a flexible plastic that may be perforated to produce the first and second sets of the plurality of holes 22, 42, which may allow passage for the fluid 5.

In most embodiments, referring to FIG. 2, the top and bottom layers 20, 40 along with the first and second sets of the plurality of holes 22, 42 may be covered with cloth material layers 24, 44. In most embodiments, the cloth material layers 24, 44 may be made from any type of fabric known in the art that may be permeable, so as to allow for the transfer of the fluid 5 or moisture to the top, middle, and bottom layers 20, 30, 40. In most embodiments, the cloth material layers 24, 44 may be made from cotton, denim, felt, linen, nylon, polyester, silk, satin, twill, wool, yarn, etc., or a combination thereof.

In most embodiments, the top layer 20 may be a cushioning material to support the foot 1. In most embodiments, the top layer 20 may be various thicknesses and may be varied in thickness through the top layer 20. In a non-limiting example, the top layer 20 may have a heel portion that may be thicker than a ball portion to better support the heel of the foot 1, as seen in FIG. 2. In most embodiment, the top layer 20 may be made with materials such as cloth, fabric, leather, foam, or any synthetic materials used in footwear industries, or a combination thereof. In most embodiments, the cushioning material of the top layer 20 may be compressible for improved comfort for the user. In some embodiments, the cushioning material may compress under the force or weight of the foot 1 when applied to the sole insert 10 and may partly decompress when removing the foot 1 from the sole insert 10.

In a preferred embodiments, the top layer 20 may be perforated with the plurality of holes 22 by hand or machine, including but not limited to a sewing machine, a mechanical press, a thermal press, a punch, a laser, or a combination thereof, to produce the first set of the plurality of holes 22. In a preferred embodiment, the first set of the plurality of holes 22 may be 1-3 mm in diameter. In some embodiments, the top layer 20 may use an alternative to plastic materials that may be an absorbent material with micro perforations. In most embodiments, the plurality of holes 22 may be space equally apart, in rows, at random, or in a designed pattern, or a combination thereof. In another embodiments, the top layer 20 may not be a perforated material as long as the bottom layer 40 may be sufficiently perforated.

In most embodiments, the moldable middle layer 30 may have a minimum thickness so that the moldable middle layer 30 may contour to an adjacent plantar aspect area 2, i.e., sole, of a user's foot 1. In most embodiments, the moldable middle layer 30 may come in contact with the fluid 5, which may be an accelerant, such as water or moisture within the shoe 3. In most embodiments, the fluid 5 may be applied by a sponge, a paper towel, a cloth towel, a spray bottle, and/or a combination thereof, which may be applied at least one of the top layer 20 or the bottom layer 40. In other embodiments, the fluid 5 or moisture may be the user's perspiration or sweat from the foot 1. In another embodiment, the fluid 5 may be a fast acting chemical accelerant. In most embodiments, after the moldable middle layer 30 contacts the fluid 5, the moldable middle layer 40 may permanently harden to conform to the adjacent plantar aspect area 2 of the foot 1. In most embodiments, the moldable middle layer 30 may be constructed from a hardening compound that may be made from various types of chemical or materials, such as potting compounds, epoxy, resins, fiberglass, fiberglass resin, etc., or a combination thereof.

In the preferred embodiment, the hardening compound may be fiberglass for desired fiberglass properties, such as strength, durability, activation speed, and ease of activation by water or ambient moisture. In most embodiments, the moldable middle layer 30, which may be constructed from the fiberglass material, may be imprinted with the adjacent plantar aspect area 2 by pressing with the foot 1 against the sole insert 10. In most embodiments, a custom foot shape 15, as illustrated in FIG. 3 as a shaded region, may permanently form in the sole insert 10 after the hardening compound, i.e., fiberglass resin, cures after contact with the fluid 5, such as moisture from an accelerant, produced by the wearer's foot 1, and/or ambient condition in the shoe 3. In most embodiments, the custom sole insert 10 may be placed in an airtight, moisture-free package to maintain freshness and to prevent unnecessary hardening.

In most embodiments, since the middle layer 30 may be constructed of various materials, a hardening agent or an accelerant used may depend on the material of the middle layer 30. In another preferred embodiment, a preferred material may be a polyurethane casting material such as that disclosed in U.S. Pat. No. 4,433,680 issued to Yoon and improved upon in U.S. Pat. No. 6,007,505 issued to Grim et al. The improvement under Grim et al. may be the addition of hydroxypropyl methyl-cellulose (HPMC), which may prevent urethane from becoming sticky when contacted with water. The preferred material according to Grim et al. may be sealed in a package and may be pliable if kept within the package or shortly after being removed. In most embodiments, the preferred material contact with the fluid 5, i.e., water, may accelerate the hardening process, but the preferred material may harden at ambient conditions without the addition of water, although at a slower rate.

In other embodiments, an alternative material that may be used as the middle layer 30 may be at least one constructed from fiberglass fabric impregnated with a water hardenable material as disclosed in U.S. Pat. No. 5,334,442 issued to Okamoto et al. The middle layer 30 may be construct of materials known in the art and not limited to the materials disclosed in the present invention. In most embodiments, other suitable materials may be used so long as said materials may be adapted to be formed to the plantar aspect area 2 of a user's foot 1 and harden to formed the custom foot shape 15 in a short period of time. In some embodiments, the middle layer 30 may be comprised of a material that may not harden at ambient conditions without first coming into contact with an activation agent, the accelerant, or the fluid 5.

In most embodiments, a required thickness of the middle material layer 30 may vary and may depend upon shoe size, width, arch height, and material considerations. In some embodiments, the required thickness may be one or more thickness sizes, as seen in FIG. 2, where a heel region may have a greater thickness than a ball region of the foot 1. In most embodiments, the required thickness may be prepackaged according to shoe size, width, arch height, and material considerations. In a non-limiting example, the wearer may be able to purchase a pair of sole inserts 12 at a drug store based on a shoe size of 8-10 and a low arched foot profile with increased heel support, i.e., the required thickness for the heel region may be 10-15 mm while the low arched foot profile may have the required thickness of about 3-5 mm. In the preferred embodiment, the preferred material may be the polyurethane casting material and hydroxypropyl methyl-cellulose material that may have a thickness range of 1-15 mm, but most preferably between 3-4 mm. In some embodiments, the insert may be limited to a general area adjacent to and about the arch of the foot 1 or may extend entire length of the foot 1, including the adjacent plantar aspect area 2, as seen in FIGS. 1-3. In another preferred embodiment, the middle moldable layer 30 may extend from under the foot 1 from the heel to a metatarsal or toe areas.

In most embodiments, the bottom layer 40 may be constructed from various types of materials such as plastics, leather, foams, etc., or a combination thereof. In most embodiments, the bottom layer 40 may have a second set of the plurality of holes 42. In a preferred embodiment, the second set of the plurality of holes 42 may be 1-3 mm in diameter. In another embodiment, the second set of plurality of holes 42 may be spaced in rows of larger holes that may be 10-15 mm in diameter expanding outwards from a center of the moldable bottom layer 40. In other embodiments, the second set of the plurality of holes 42 may be comprised of both the 1-3 mm and the 10-15 mm diameter holes in any type of pattern or at random on the bottom layer 40. In some embodiments, the bottom layer 40 may use an alternative to plastic materials that may be an absorbent material with micro perforations. In most embodiments, the second set of the plurality of holes 42 may be constructed in a similar manner as the first set of the plurality of holes 22.

In most embodiments, the plantar aspect area of the wearer's foot 1 may be imprinted on to the molding middle layer 30 as the wearer walks. In most embodiments, once the middle layer 30 may have hardened, the bottom layer 40 may retain or conform to the shape of the wearer's foot 1 permanently in conformity with the molding middle layer 30. In these embodiments, the bottom layer 40 may be a moldable bottom layer.

In most embodiments, the shape of the sole insert 10 may be personalized to fit certain types of foot deformities or foot shapes by adding a padding support 50, as seen in FIG. 2, to certain areas on the foot 1 that may realign the foot 1 in a certain direction during the molding phase or provide additional support to the sole insert 10 for a sufficient period of time. In some embodiments, the padding support 50 may have a third plurality of holes 52, not shown, that may allow for the fluid to pass through. The third plurality of holes may have properties similar to the first and second plurality of holes 22, 42. In most embodiments, the padding support 50 may be any size, shape, thickness, and/or malleable property that may conform with the size, shape, and thickness of the sole insert 10. In a non-limiting example referring to FIG. 2, the padding support 50 may be placed near the heel portion of the bottom layer 40 to improve shock absorbance for the user when the sole insert 10 is used with athletic shoes. In this example, the user may be purchasing the sole insert 10 in conjunction with a sports activity like basketball or soccer. The prepackaged sole insert 10 may be specialized for a sport category of use and may be advertised as such.

In most embodiments, the bottom layer 40 may provide an upward normal force so that the moldable middle layer 30 may be sandwiched between the upward normal force of the bottom layer 40 and a downward force the foot 1 that may be applied to the top layer 20. In most embodiments, the bottom layer 40 may be constructed from various types of materials, such as foam, elastic bandages, vacuum suction cups, plastics, etc., or a combination thereof. In the preferred embodiment, the bottom layer 40 may be constructed from plastic materials because the plastic materials may be flexible and occupy much less volume in the shoe 3. In most embodiments, as seen in FIG. 2, the bottom layer 40 may sufficiently perforated to allow the fluid 5 or moisture to be absorbed into the moldable middle layer 30.

In most embodiments, the bottom layer 40 may cover the foot 1 from the heel region to an area under the ball region of the foot 1. In most embodiments, an inside surface of the bottom layer 40 may have a cavity 46 that may be fitted to the moldable middle layer 30. In most embodiments, the bottom layer 40 may have a narrow rim 48 around the cavity 46 for attachment to the top layer 20. In some embodiments, the narrow rim 48 may have an adhesive that may adhere to at least one side 38 of the moldable middle layer 30 and/or to a perimeter 28 of the top layer 20 as shown in FIG. 2. In some embodiments, the rim 48 of the bottom layer may be formed to be a soft and flexible material to avoid wrinkles that may form along a medial and lateral area of the sole insert 10. In other embodiments, the rim 48 may have a plurality of cuts that may absorb the wrinkles along the medial and lateral area of the sole insert 10.

In some embodiments, the sole insert 10 may include the additional padding 50 as a heel seat that may cover an area around the heel. In some embodiments, the heel seat may be positioned below the middle layer 20 and above the bottom layer 40. In some embodiments, a top surface of the heel seat may be constructed as a rounded surface or or a flat surface about a central area of the heal seat to provide more stability to the user while he or she may be standing and applying a downward force with the foot 1.

Assembly

The method for construction and activating the insert sole 10 will now be described. In most embodiments, the top, middle, and bottom layers may be preconstructed or preformed, where the rim 48 of the bottom layer 40 and the perimeter 28 of the top layer 20 may be attached about their respective periphery or perimeter, preferably with an adhesive, a glue, and/or epoxy. In most embodiments, before the top and bottom layers 20, 30 are sealed, the middle layer 30 may be inserted between the top layer 20 and the bottom layer 40. In other embodiments, the top and bottom layers 20, 40 may be sealed on at least one side before the the middle layer 30 may be inserted. In some embodiments, the padding support 50 may be positioned on the inside surfaces of the top layer 20 and the bottom layer 30, as seen in FIG. 2. In a preferred embodiments, the adhesive, the glue, and/or the epoxy may be applied to the top, middle, and bottom layers 20, 30, 40 to maintain all three layers 20, 30, 40 as a single sole insert 10. In some embodiments, stitching, thermal adhesive, adhesive, glue, or epoxy or some other physical attachment means may be used to ensure the layers 20, 30, 40 remain sandwiched together as the single sole insert 10.

In some embodiments, the cloth cover layers 24, 44 may cover the top and bottom surfaces, respectively, of the top and bottom layers 20, 40. In most embodiments, an additional adhesive, an additional glue, or an additional epoxy may be used to secure the cloth cover layers 24, 44. In other embodiments, stitching or some other physical attachment means may be used to ensure the cloth material layers 24, 44 remain sandwiched together with the single sole insert 10.

In most embodiments, when at least the top, middle, and bottom layers 20, 30, 40, and optionally the additional padding 50 and cover layers 24, 44 are sandwiched together, the sole insert 10 may be stored in an airtight moisture-proof packaging. In some embodiments, the pair of sole inserts 12 may be stored together in the airtight moisture-proof packaging or may be individually packaged. In other embodiments, a plurality of the pair of sole inserts 12 may be stored in a resealable moisture-proof package. In most embodiments, the sole insert 10 or pair of sole inserts 12 may be sold directly to the user or prescribed to the user by a podiatrist once packaged. This allows the user to have immediate access to the customizable sole insert 10 that may be used at the user's current location.

Instructions for Use

Continuing with the above method with regards to two different activation techniques. In some embodiments, the user may select an appropriate category of packaged sole inserts 10 and may open the airtight moisture-proof package to receive one or more sole inserts 10. The user may then apply directly to the surface of the sole insert 10 a sufficient amount of moisture or the fluid 5, such as an accelerant or water. Where the sufficient amount of moisture or the fluid 5 may depend upon shoe size, width, arch height, and material considerations. In most embodiments, the moldable middle layer 30 of the sole insert 10 may harden by at least one of an accelerated process technique or a standard process technique.

In some embodiments, the acceleration process technique may harden the moldable middle layer 30 with a reduce curing time of about 10-15 minutes. In most embodiments, a user may gently use a wet sponge, paper towel or other moisture source to deliver the sufficient amount of moisture or the fluid 5 through the perforated top layer 20 into the moldable middle layer 30. The application of the fluid 5 may seep or flow through the first plurality of holes 22 of the top layer 20 to contact an upper surface of the middle layer 30.

In most embodiments, the user may then turn the sole insert 10 over so that the perforated bottom layer 40 faces upwards and may gently press the wet sponge or the wet paper towel against the bottom face of the bottom layer 40 several times to transfer the sufficient amount of moisture or the fluid 5, i.e., water, through the plurality of holes 42 and into the moldable middle layer 30. In most embodiments, the sole insert 10 may be placed into the shoe 3 and the user may press or walk on the sole insert 10 for at least 5 minutes or until the moldable middle layer 30 hardens. In most embodiments, the user may remove his or her foot 1 from the shoe 3 and may wait at least 10 minutes for the middle layer 30 of the sole 10 to cure.

In other embodiments, the standard process technique may harden the moldable middle layer 30 with a curing time of at least 4 hours without directly applying the fluid 5 to the top layer 20 and/or bottom layer 40. In most embodiments, the sole insert 10 may be placed directly into the shoe 3 and the user may walk on the sole insert 10 for at least 30 minutes without applying the fluid directly to the top and bottom layers 20, 40. In most embodiments, the ambient moisture within the shoe 3 or the perspiration of the user's foot 1 may interact with the sole insert 10. In most embodiments, the user may remove his or her foot 1 from the shoe 3 while leaving the sole insert 10 inside the shoe 3 to cure for the next 4 hours. In an alternative embodiment, the sole insert 10 may be worn and used in the shoe 3 for several hours until the sole insert 10 cures.

In most embodiments, the user may remove the sole insert 10 from the shoe 3 when no longer needed, heavily worn, dirty, or no longer hygienic, i.e., odor, discoloration, or contamination. The sole insert 10 may be disposed of via conventional means. The plurality of sole inserts 10 may improve hygiene or odor because they may be readily replaced. The plurality of sole inserts 10 may allow the user to create a plurality of customizable sole inserts 10 that may be placed in a plethora of shoes 3 to conform with each individual shoe 3.

In most embodiments, the sole insert 10 may be manufactured in various sizes, widths, and arch heights so that a person may select the proper sole insert 10 to fit within an intended size and width of shoe 3. In most embodiments, the sole inserts 10 may have several options or categorizes of use for said sole insert 10 described herein. In most embodiments, the several options or categorizes may be made as removable orthotics or sole inserts 10 for athletic, walk, casual, dress shoes, or a combination thereof. In some embodiments, the sole inserts 10 may be built into a portion of the shoe 3 as part of an added value to any type shoe available.

With respect to the above description, it is to be realized that any of the above embodiments may readily be combined with any one or more embodiments also listed above. In particular, with respect to the above description, it is to be realized that the optimum dimensional relation ships for the parts of the present invention may include variations in size, materials, shape, form, function and manner of operation. The assembly and use of the present invention are deemed readily apparent and obvious to one skilled in the art. 

1. A customizable sole insert for a shoe, the sole insert comprising: a top layer having a first plurality of holes through the top layer; a middle layer having a conforming and curable hardening material; a bottom layer having a second plurality of holes through the bottom layer; wherein the top layer, middle layer, and bottom layers are fastened together by a fastener; wherein a fluid applied to the middle layer causes the middle layer to cure; wherein the middle layer conforms to a plantar aspect area or sole of a foot of a user.
 2. The sole insert of claim 1, further comprising: a top cover attached to to a top outside surface of the top layer; and, a bottom cover attached to a bottom outside surface of the bottom layer; wherein the top cover and the bottom cover are made of a cloth material; wherein the cloth material is at least one of a cotton material, a denim material, a felt material, a linen material, a nylon material, a polyester material, a silk material, a satin material, a twill material, a wool material, and a yarn material.
 3. The sole insert of claim 1, wherein the first plurality of holes allow for the fluid to pass through the top layer to contact the middle layer, wherein the fluid is moisture produced by a user's foot.
 4. The sole insert of claim 1, wherein the second plurality of holes allow for the fluid to pass through the bottom layer to contact the middle layer, wherein the fluid is water applied by a user.
 5. The sole insert of claim 1, wherein the conforming and curable hardening material is at least one of potting compounds, epoxy, resins, fiberglass, fiberglass resin, polyurethane casting, and hydroxypropyl methyl-cellulose.
 6. The sole insert of claim 1, wherein the top layer is made from a cushion material; wherein the cushion material compresses under a foot of a user; wherein the cushion material partly decompress when the foot of the user is removed from the sole insert.
 7. The sole insert of claim 1, wherein the bottom layer is conformable to the middle layer.
 8. The sole insert of claim 1, wherein the bottom layer has a protruding rim.
 9. The sole insert of the claim 8, wherein the protruding rim is attachable to a perimeter of the top layer by the fastener, wherein the fastener is at least one of an adhesive, a glue, an epoxy, and stitching.
 10. The sole insert of claim 1, further comprising: at lease one additional padding positioned below the top layer or above the bottom layer.
 11. The sole insert of claim 10, wherein the at least one additional padding acts as a heel support.
 12. A method for manufacturing a customizable sole insert, the method comprising: forming a bottom layer having a protruding rim on a perimeter of the bottom layer; wherein the protruding rim forms a cavity in the bottom layer; applying an adhesive in the cavity of the bottom layer; inserting a middle layer within the cavity of the bottom layer; wherein the middle layer hardens when contacted by a fluid; applying the adhesive to the protruding rim and a top surface of the middle layer; sandwiching a top layer onto the protruding rim and the top surface of the middle layer; wherein the top layer and the bottom layer have a first and second set of plurality of holes.
 13. The method for manufacturing a customizable sole insert 12, wherein the method further comprises: applying the adhesive to at least one of an outer surface of the top and bottom layers; covering at least one of the top and bottom layers with a cover; wherein the cover is made from a permeable cloth material; and, placing the sole insert into a moisture proof packaging.
 14. The method for manufacturing a customizable sole insert 12, wherein the method further comprises: inserting at least one additional padding below the top layer and above the bottom layer.
 15. A method for activating a customizable sole insert, the method comprising: selecting a sole insert from a selection of inserts; wherein the selection of inserts are based on various shoe sizes, widths, arch heights and categories of use; applying a fluid to a first plurality of holes in a top layer; wherein the fluid passes through the top layer via the first plurality of holes to contact a middle layer; rotating the sole insert so that an outer surface of a bottom layer faces in the up direction; applying the fluid to a second plurality of holes in the bottom layer; wherein the fluid passes through the bottom layer via the second plurality of holes to contact the middle layer; inserting the sole insert into a shoe; placing a foot of a user into the shoe applying a downwards force on the sole insert for a first period of time; wherein the downwards force molds the middle layer; removing the foot of the user from the shoe and leaving the sole insert in the shoe for a second period of time.
 16. The method for activating the customizable sole insert 15, wherein the fluid is water; wherein the fluid is applied by a sponge, a paper towel, or a cloth.
 17. The method for activating the customizable sole insert 16, wherein the first period of time is at least 5 minutes; wherein the second period of time is at least 10 minutes.
 18. The method for activating the customizable sole insert 15, wherein the fluid is ambient moisture produced by the foot of the user; wherein the ambient moisture is produced when the foot is inserted into the shoe and the user walks for the first period of time with the insert placed in the shoe.
 19. The method for activation the customizable sole insert 18, wherein the first period of time is is at least 30 minutes; wherein the second period of time is 4 hours.
 20. The method for activating the customizable sole insert 15, wherein the middle layer is made from polyurethane casting material and hydroxypropyl methyl-cellulose; wherein contact from the fluid causes the polyurethane casting material and hydroxypropyl methyl-cellulose to harden. 